Mineral Processing Design

Foreword.- 1 - Applied Mineralogy in Ore Dressing.- 1. Introduction.- 2. Studies On Uncrushed Ores.- 3. Studies of Crushed Mill Products.- 3.1 Metal and Mineral Balances.- 3.2 Mineral Liberation.- 3.3 Free Grains.- 3.4 Unliberated Grains.- 4. Applied Mineralogy in Circuits Treating Volcanogenic Ores.- 4.1 Cu-Pb Circuits.- 4.2 Copper-Lead Separation Circuits.- 4.3 Lead Circuit.- 4.4 Zinc Circuit.- 4.5 Tin Circuit.- 5. Examples of Beneficiation Problems Explained by Mineralogical Studies.- 6. Equipment for Performing Mineralogical Analysis.- 7. Methods of Mineral Identification.- 8. Methods of Determining Mineral Compositions.- 9. Methods of Determing Mineral Quantities.- 10. Methods of Determining Mineral Liberation and Size Distributions.- 11. Presentation of Data.- 11.1 Presentation of Data for Mill Products.- 11.2 Modal Analysis.- 11.3 Proportion of Minerals as Free Particles or Unliberated Mineral Grains.- 11.4 Percent Inclusions of Unliberated Valuable Minerals.- References.- 2 - Chemistry osf Sulfide Mineral Flotation.- 1. Introduction.- 1.1 Sulfide Minerals-Water-Oxygen System.- 2. Modulation of Collector Coating.- 2.1 Hydrophobization of Sulfides by Xanthate Coating.- 2.2 Hydroxyl Ion as a Depressant and Critical pH Values.- 2.3 Cyanide as a Depressant.- 2.4 Sulfide as a Depressant.- 3. Electrochemical Studies.- 3.1 Galena-Oxygen-Xanthate Flotation System.- 3.2 Favorable Area for Flotation of Galena on a Potential-pH Diagram.- 4. Silver Sulfide Electrode and Its use in Controlling Flotation of an Oxidized Lead-Zinc Ore.- 4.1 Silver Sulfide-Xanthate-Oxygen System.- 4.2 Concentration of an Oxidized Lead-Zinc Ore.- References.- 3 - Coal Flotation.- 1. Introduction.- 2. Structure and Composition of Coal, Affecting Coal Flotation.- 2.1 Chemical and Petrographic Compositin of Coal, Affecting Coal Flotation.- 2.2 Impurities Associated with Coal.- 2.3 Natural Flotability of Coal.- 2.4 Effect of Oxidation on Coal Flotability.- 3. Operational Factors Related to Coal.- 3.1 Reagents Used in Coal Flotation.- 3.1.1 Non-Polar Oils.- 3.1.2 Heteropolar Reagents.- 3.1.3 Inorganic Electrolytes.- 3.1.4 Depressants.- 3.2 pH and Zeta-Potential.- 3.3 Size and Specific Gravity of Particles.- 3.4 Pulp Density and Temperature.- 3.5 Presence of Slime.- 3.6 Feed Rate.- 3.7 Conditioning Time.- 3.8 Air Flow Rate.- 3.9 Type of Flotation Machines.- 3.10 Flotation Circuit.- 4. Cost of Coal Preparation Plant.- 5. Conclusion.- References.- 4 - Gravity Concentration Methods.- 1. Introduction.- 2. Principles.- 3. Mechanism of Concentration.- 4. Unit Processes.- 4.1 The Duty Required.- 4.2 Size Range.- 4.3 Throughput.- 4.4 Efficiency.- 4.5 Heavy Medium Separation.- 4.6 Jigging.- 4.7 The Sluice Box or Palong.- 4.8 The Pinched Sluice and Reichert Cone.- 4.9 Spiral Concentration.- 4.10 Shaking Tables.- 4.11 Slime Plants.- 4.12 Dry Gravity Concentration.- 5. Testing for Gravity Concentration.- 6. Plant Operations.- References.- 5 - Processing of Mineral Ores by Modern Magnetic Separation Techniques.- 1. Introduction.- 2. Particle Entrapment Devices.- 3. The Kolm-Marston 'High Gradient' Magnetic Separation.- 4. Particle Deflection Devices.- 5. Prototype OGMS Systems.- 6. Projected Future Developments.- References.- 6 - The Methodology of Froth Flotation Testwork.- 1. Introduction.- 2. Objectives and Evaluation Criteria.- 3. Mineral Appraisal.- 3.1 Sampling.- 3.2 Chemical Assay.- 3.3 Mineralogy.- 4. Types of Flotation Testwork.- 4.1 Small Scale Tests.- 4.2 Batch Flotation Tests - "One-variable-at-one-time".- 4.3 Batch Flotation Tests - time samples.- 4.4 Locked Cycle Tests.- 4.5 Pilot Plant Tests.- 5. Statistical Aspects of Flotation Testwork.- 5.1 Planning the Experiment.- 5.2 Significance Testing.- 5.2.1 The t-distribution.- 5.2.2 The F-test.- 5.3 Analysis of Variance (ANOVA).- 5.3.1 Flotation Test. One-way ANOVA.- 5.3.2 Flotation Test. Two-way ANOVA.- 5.4 Reduction of Factors.- 5.5 Calculation of Results, Criterion of Success and Error.- 6. Model Development and Optimization.- 6.1 Kinetic Model.- 6.1.1 Batch Tests.- 6.1.2 Pilot Plant Kinetic Model.- 6.2 Factor Models.- 6.3 Optimization.- 6.4 Scale-up.- References.- 7 - Mineral Processing Flowsheet Development.- 1. Introduction.- 2. Objectives of Metallurgical Testing.- 3. Choice of Sample(s) for Metallurgical Testing.- 4. Laboratory Testwork Programming.- 4.1 Pertinent information to Collect.- 4.2 Planning the Metallurgical Testwork.- 5. Execution of the Laboratory Batch Testwork.- 6. Cycle Tests.- 7. Complementary Testwork for Design Purposes.- 8. Pilot Plant Testwork.- 9. Final Recommendations.- References.- 8 - Mass Balance Equilibration.- 1. The Origin and Classification of Errors.- 2. The Need for Systematic Approach to Data Validation.- 3. Principles of Mass Balance Computation.- 4. Application to a Grinding-Classification Process.- 5. Extended Balance Equilibration.- 5.1 The Variables Classification and the First Decomposition.- 5.2 Partitioning the Network.- Partitioning the Equations.- Mass Balance Equilibration.- A Computer Aided Design System Dedicated to the Data Valiation Problem.- References.- 9 - Concentrating Plant Design-Capital and Operating Costs.- 1. Concentrating Plant Design.- 1.1 Mill Design.- 1.2 Mill Layout.- 1.3 Design Features.- 1.4 Crushing, Grinding, and Classification.- 1.5 Flotation.- 1.6 Flotation Products Handling.- 1.7 Energy Consumption.- 1.8 Environmental Problems.- 1.9 Porphyry Copper Ores.- 1.10 Lead-Zinc Ores.- 2. Capital Costs.- 2.1 General.- 2.2 Pre-feasibility Engineering.- 2.3 Feasibility Engineering.- 2.4 Construction Engineering.- 2.5 Project Reports.- 2.6 Examples.- 3. Operating Costs.- 3.1 Introduction.- 3.2 Operating Cost Distribution.- 3.3 Examples.- References.- 10 - Simulation in Mineral Processing.- 1. Introduction.- 2. Methodology.- 2.1 Simulation.- 2.2 Rate Equation.- 2.3 Optimization.- 3. Experimental Example.- 4. Conclusion.- References.- 11 - Slurry Pipeline Transport of Minerals and Coal.- 1. Introduction.- 1.1 Major Applications of Conventional Slurry Pipelines.- 1.2 Major Applications of Coarse-Coal Slurry Pipelines.- 1.3 Coarse-Coal Ship Loading/Unloading.- 2. Technical Aspects of Slurry Pipeline System Components.- 2.1 Slurry Pumps.- 2.2 Pumping Stations.- 2.3 Line Pipe.- 2.4 Pipeline Construction.- 2.5 Coal Slurry Preparation Facility.- 2.6 Coal Slurry Dewatering Facility.- 2.7 Operational Characteristics.- 2.8 Communication and Control Systems.- 3. Hydraulics of Slurry Flow in Pipelines.- 3.1 Behavior and Classification of Slurry Flows in Pipes.- 3.2 Hydraulic Design Criteria for Homogenous Slurries.- 3.3 Hydraulic Design Criteria for Heterogeneous Slurries.- 3.4 Hydraulic Design Criteria for Hetero-Homogeneous Slurries.- 3.5 Hydraulic Design Criteria for Coarse Solids Slurries.- 3.6 Hydraulic Design Criteria for Non-Conventional Slurries.- 4. System Component Cost Estimating Methodology.- 4.1 Summary of Cost Estimate Relationships.- 4.2 Selected Results for a Coal Slurry Pipeline in Virginia.- 4.3 A Simplified Optimization Methodology.- 4.4 Transportation Cost.- 5. Brief Assessment of Energy, Economic, and Environmental Aspects of Slurry Pipelines.- 5.1 Energy Aspects.- 5.2 Economic Aspects.- 5.3 Environmental Aspects.- 6. Conclusions.- References.- List of Participants.- Author Index.